Instruction Manual IM/9408 CAR_3 Dissolved Oxygen Cartridge Electrode Systems 9408 8000 Series
ABB The Company EN ISO 9001:1994 We are an established world force in the design and manufacture of instrumentation for industrial process control, flow measurement, gas and liquid analysis and environmental applications. As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and support worldwide. We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support. The quality, accuracy and performance of the Company s products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology. The NAMAS Calibration Laboratory No. 055 is just one of the ten flow calibration plants operated by the Company, and is indicative of our dedication to quality and accuracy. Cert. No. Q05907 EN 9001 (ISO 9001) Lenno, Italy Cert. No. 9/90A Stonehouse, U.K 055 Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the Technical Publications Department. Health and Safety To ensure that our products are safe and without risk to health, the following points must be noted: 1. The relevant sections of these instructions must be read carefully before proceeding.. Warning labels on containers and packages must be observed. 3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given. 4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and/ or temperature. 5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used. 6. When disposing of chemicals ensure that no two chemicals are mixed. Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be obtained from the Company address on the back cover, together with servicing and spares information.
CONTENTS 1 INTRODUCTION... 1.1 Purpose... 1. Systems and Cartridges... INSTALLATION... 3.1 Typical Installation... 3. Water Supply for Water Wash Systems... 3.3 Fitting the Dissolved Oxygen Sensor... 4.4 Installing the Cartridge... 4 3 CALIBRATION... 5 4 MAINTENANCE... 6 4.1 General Cleaning... 6 4. Calibration Requirement... 6 4.3 Replacing the Oxygen Sensor... 6 5 SPARES... 7 6 SPECIFICATION... 8 1
1 INTRODUCTION 1.1 Purpose Fig. 1.1 This instruction manual describes the installation and maintenance of the 9408-8000 Series Dissolved Oxygen System. Cartridge & Flowcell Assembly 1. Systems and Cartridges Fig. 1.1 Systems comprise a cartridge and a 'T' piece flowcell with connection fittings. The table below summarizes the available combinations of pipe size/connection type, cable length and cleaning option. Part numbers for individual items are listed in the Spares Section. Electrode O Ring Flowcell O Ring Dissolved Oxygen System 9408/ 8 X X X Process connections 1" BSP 0 1 / " BS P 1 1" NPT 1 / " NP T 3 Cable length in metres 1 0 3 1 5 10 3 0 4 Cleaning Without cleaning 0 With cleaning 'T' Piece Flowcell Water Wash from Solenoid Valve Electrode In-line System 1" BSP or 1" NPT Option 1 /" BSP or 1 /" NPT insert option Mains in Relays Current Output Note. Tube not supplied. Optional Water Wash System Fig. 1.1 System Schematics
INSTALLATION.1 Typical Installation A typical installation is shown in Fig..1. A recommended installation for samples which may have entrained air or are subject to intermittent flow is shown in Fig.. Vent To prevent spillage when cartridge is removed. To prevent spillage when cartridge is removed. To ensure that the cartridge is always in solution. A Approximately 15 Point B must be lower than point A to ensure that the cartridge is always in solution. B Drain Sample Flow Fig..1 Typical Installation Drain. Water Supply for Water Wash Systems Fig..3 and.4 Important Note. Installation must only be carried out in accordance with the local water authority and council bylaws. Caution. The maximum water pressure at the electrode should not exceed 4 bar. At NO time should the sample pressure be allowed to exceed that of the Water Wash water supply. Fit a non return valve if this possibility exists. Fig.. Recommended Installation for Samples with Entrained Air or Intermittent Flow Information. As all quick-fit connectors used in Water Wash systems incorporate cutoff valves, tubes may subsequently be disconnected on operational equipment without sample loss or Water Wash discharge. Note. For optimum performance of the Water Wash function in flow systems, the sample pressure should be at least bars lower than that of the Water Wash water supply. The water supply for the Water Wash system must come from a suitable supply via a solenoid valve. The general specification for the solenoid valve is: Install a suitable solenoid valve (user supplied) to the mains water supply feed see Important Note and Caution, above. 1 Brass body: /, NC Orifice size: 3.0 / 4.0 mm Port size: 1 /8" 1 /4" BSP Pressure: 0 to 6 bar Coil: 110/115 V a.c. or 30/40 V a.c. 50/60 Hz Before fitting the electrode cartridge system, install the water supply as shown in Fig..3. Note. See Fig..3 for recommended tubing. 3 Connect a suitable length of 1 /4" i.d. p.v.c. tube to the outlet of the solenoid valve. This tube terminates at the electrode installation point. Push the quick-fit connector supplied, onto the free end of the tube. Note that the quick-fit connector incorporates a cut-off Note. It is advisable to use a suitable hose clamp. Temperature Compensator Water Wash Nozzle Sensor Fig..3 Installing the Water Wash Water Supply Fig..4 Location of Water Wash Nozzle 3
INSTALLATION.3 Fitting the Dissolved Oxygen Sensor Fig..5 1 Remove dummy sensor from the cartridge. Caution. It is imperative to avoid damaging the membrane. EXTREME care must be taken when handling the sensor. Access the new sensor by unscrewing the sensor housing. 3 Unscrew the sensor from the shorting cap using the reverse end of the sensor housing as a tool. 4 Remove and discard the rubber sealing ring from the new sensor. 5 Dry the sensor with a paper tissue taking care not to damage the delicate, transparent membrane covering the silver cathode. Ensure that the gold contacts, and the threaded portion of the sensor are clean and completely dry. Fit the new sealing ring supplied see 4 above and screw the sensor into the cartridge body by hand, firmly. 6 7 Reverse the sensor housing and locate the lugs into the keyways on top of the sensor.then using the sensor housing as a tool, tighten the sensor firmly by hand to ensure a good seal. Fig.5 Fitting the Dissolved Oxygen Sensor.4 Installing the Cartridge a) Fit the flowcell into the pipeline observing all safety precautions. Fit isolating valves where necessary to enable safe access to the sensor for maintenance purposes. b) Ensure that all connections are tight. c) Connect the end of the cable from the cartridge to the 4600 Series Transmitter see Tables.1 and. and the appropriate 4600 Series manual. Table.1 Connections to the 4640 Dissolved Oxygen Transmitter Sensor Temperature Compensator 4640 Terminal Wire No. 1 +ve (red) 3 -ve (blue) 4 screen 5 black 6 green 7 yellow Table.1 Connections to the 4645 Dissolved Oxygen Transmitter Temperature Compensator Sensor 4645 TBB Terminal Wire No. 6 yellow 6 green 8 black 10 -ve (blue) 11 1 +ve (red) Connect the screen to the earth stud on the case. f) Calibrate see Section 3. g) For Water Wash systems, snap on the water feed pipe from the solenoid valve see Fig..6. h) Visually check water cleaning action by switching on the Water Wash option on the 4600 transmitter. There should be a vigorous jet of water sprayed across or onto the sensor membrane. 4
INSTALLATION i) Ensure that all pipeline connections are securely fitted. Apply PTFE tape to the threads of the 1" NPT cartridge to effect a water tight seal, and check that the O ring and sealing area are clean on bayonet. j) Fit the electrode cartridge to the flowcell. 3 CALIBRATION The procedures for zero and span calibration are fully described in the 4600 Series Transmitter Operating Instructions to which reference should be made. Note. It is advisable to switch off the Water Wash before starting the calibration procedure. This can be done either by turning off at the transmitter unit, or by disconnecting the quick-fit connector. 1 Push on firmly to connect. To release, press the metal catch and the connector is ejected. Tube to solenoid valve Quick-fit Connector 1) Isolate the flowcell. ) Remove the system from its mounting bracket. Caution. It is imperative to avoid damaging the membrane when removing the cartridge (with sensor) from the flowcell. Use EXTREME care in step 3). 3) Remove the cartridge from the flowcell. 4) Wash the exposed sensor capsule CAREFULLY with clean water. 5) Calibrate as instructed in the 4600 Series Transmitter Operating Instructions. 6) Re-enable the Water Wash (if applicable). 7) Again, use EXTREME care when fitting the cartridge into the flowcell to avoid damaging the membrane; remount on the bracket and restore the sample. Fig..6 Water Wash System Quick-fit Connection 5
4 MAINTENANCE Regular maintenance is limited to periodic cleaning and calibration. 4.1 General Cleaning To ensure accurate monitoring, the sensor membrane must be kept clean by periodic washing. The frequency depends on the particular application. Caution. It is imperative to avoid damaging the membrane. EXTREME care must be taken when handling the sensor. 4. Calibration Requirement Regular calibrations keep the system operating at the optimum level. Calibration also gives an early indication of degrading sensor performance. See Section 3 for the calibration procedure. 4.3 Replacing the Oxygen Sensor The sensor is replaced whenever the existing one becomes exhausted. Typical sensor life is approximately 1 months. Wash the membrane using clean water and a soft cloth or tissue. Storage DO: use sensors in date rotation to prevent them being stored longer than necessary. at all times, store sensors in a dry and cool environment. store sensors in a refrigerator to extend their life, but DO NOT allow them to freeze. DO NOT: allow sensors to dry out, either in storage or in use. leave sensors in vehicles where they are likely to freeze or be exposed to high temperatures. leave sensors on-site without protection from direct sun or high temperatures. use the sensor if it's sealed environment has dried out. 1 Isolate and remove the cartridge from the flowcell. Caution. Clean and dry the area around the sensor capsule before removal, as indicated below. 3 Use the sensor housing as a tool to unscrew the old sensor from the cartridge body (see 9 for method); discard the old capsule in accordance with local regulations. Dry the cartridge body with a paper tissue; ensure that the gold electrical contacts, and the recess into which the capsule screws, are clean and completely dry. Caution. Do not leave the new sensor exposed to air for more than 30 minutes as the membrane will dry out. Ensure the following steps are done carefully to avoid damaging the membrane covering the silver cathode. 4 Access the new capsule by unscrewing the capsule housing 5 6 Unscrew the capsule from the shorting cap using the reverse end of the capsule housing as a tool. Remove and discard the rubber sealing ring from the new capsule. 7 8 Dry the sensor with a paper tissue taking care not to damage the delicate, transparent membrane covering the silver cathode. Ensure that the gold contacts, and the threaded portion of the sensor are clean and completely dry. Fit the new sealing ring supplied see 6 above and screw the sensor into the cartridge body by hand. 9 Reverse the sensor housing and locate the lugs into the keyways on top of the sensor.then using the sensor housing as a tool, tighten the sensor firmly by hand to ensure a good seal. 10 Calibrate the cartridge see Section 3. 11 Finish the installation see Section.4. Fig. 4.1 Procedure for Changing the Sensor Capsule 6
5 SPARES Dissolved Oxygen Sensor... 801 170 Cartridges D.O. cartridge, 1 m cable... 9408 800 D.O. cartridge, 3 m cable... 9408 801 D.O. cartridge, 5 m cable... 9408 80 D.O. cartridge, 10 m cable... 9408 803 D.O. cartridge, 0 m cable... 9408 804 D.O. cartridge, special cable length... 9408 809 Additional Spares for Water Wash systems only End Cap Quick-fit in-line connector 1 /4" barb... 01651 End Cap Quick-fit connector insert panel mount 1 /8" hose barb... 016513 Cartridge Quick-fit in-line connector 1 /8" barb... 016514 Tubing specify length: 1,, 3, 5, 10, 0 metres or special length... 01141 Hose clamp for tubing above... 015163 Cartridges + Water Wash D.O. cartridge, 1 m cable... 9408 810 D.O. cartridge, 3 m cable... 9408 811 D.O. cartridge, 5 m cable... 9408 81 D.O. cartridge, 10 m cable... 9408 813 D.O. cartridge, 0 m cable... 9408 814 D.O. cartridge, special cable length... 9408 819 7
6 SPECIFICATION Materials of construction... Glass-coupled polypropylene Operating temperature range... 5 C to 40 C Operating pressure... Atmospheric Temperature compensation... Automatic correction by means of an integral Pt100 resistance sensor Accuracy... ±0. mg/l or ±% saturation within ±10 C of the calibration temperature within the range 0 C to 35 C Response... Typically 0 seconds for 90% step change of oxygen concentration at 0 C Pressure rating... bar Flow rate... litres a minute minimum Process connections... 1 /" and 1" BSP and 1 /" and 1" NPT Cable lengths... 1, 3, 5, 10 and 0 metre (standard options). With a suitable junction box fitted, a maximum 100 metre cable can be used part number 033 88. 8
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ABB has Sales & Customer Support expertise in over 100 countries worldwide www.abb.com The Company s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice. Printed in UK (05.05) ABB 005 IM/9408 CAR Issue 3 ABB Limited Oldends Lane, Stonehouse Gloucestershire GL10 3TA UK Tel: +44 (0)1453 86661 Fax: +44 (0)1453 89671 ABB Inc. Analytical Instruments 9716 S. Virginia St., Ste. E Reno, Nevada 8951 USA Tel: +1 (0) 775 850 4800 Fax: +1 (0) 775 850 4808